Catalyst for selective opening of cyclic naphtha and process for using the catalyst

ABSTRACT

A catalyst and process for opening aliphatic cyclic hydrocarbons have been developed. The catalyst comprises a catalytic metal component, a molecular sieve and refractory inorganic oxide component. The molecular sieve is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof. Preferred catalytic metals include platinum, palladium and rhodium. The catalyst may also contain a modifier such as niobium, titanium, or rare earth metals.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Division of copending application Ser. No. 11/268,835, filed Nov. 8, 2005, which in turn is a Continuation-In-Part of application Ser. No. 10/704,485, filed Nov. 7, 2003, now abandoned, the contents of which are hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to a catalyst for the selective ring opening of cyclic naphtha which comprises a catalytic metal component, a molecular sieve and a refractory oxide component. The molecular sieve is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof. Optionally the catalyst may contain a modifier. This invention also relates to a process for selective ring opening using the catalyst.

BACKGROUND OF THE INVENTION

Olefins are used in various reactions to produce important chemical compounds. Accordingly, demand for olefins is ever increasing and therefore new processes or increased efficiencies in existing processes are required. One of the main processes used in preparing light olefins is naphtha steam cracking. It is known that the efficiency of steam cracking depends on the specific composition of the naphtha feed. Specifically it has been demonstrated that converting naphthenes to acyclic paraffins, e.g. n-paraffins significantly improves olefin yield from the steam cracker. There is, therefore, a need for an improved ring opening catalyst.

Improved ring opening catalysts are also necessary because of increasing demand for environmentally friendly products and clean burning high performance fuels. In this case naphthene rings are opened to give acyclic paraffins which in turn can be isomerized. These isomerized paraffins have improved characteristics than the corresponding naphthenes.

An increased amount of paraffins is also required in providing reformulated gasoline. Reformulated gasoline differs from the traditional product in having a lower vapor pressure, lower final boiling point, increased content of oxygenates, and lower content of olefins, benzene and aromatics.

Reduction in gasoline benzene content often has been addressed by changing the cut point between light and heavy naphtha, directing more of the potential benzene formers to isomerization instead of to reforming. No benzene is formed in isomerization, wherein benzene is converted to C₆ naphthenes and C₆ naphthenes are isomerized toward an equilibrium mixture of cyclohexane and methylcyclopentane or converted to paraffins through ring opening. It is believed that such C₆ cyclics are preferentially adsorbed on catalyst sites relative to paraffins, and the cyclics thus have a significant effect on catalyst activity for isomerization of paraffins. Refiners thus face the problem of maintaining the performance of light-naphtha isomerization units which process an increased concentration of feedstock cyclics.

Catalysts which are useful for ring opening are known and include a high chloride platinum component dispersed on a refractory inorganic oxide which is described in U.S. Pat. No. 5,463,155. U.S. Pat. No. 5,811,624 describes a catalyst for the selective opening of 5 and 6 membered rings which consists of a transition metal catalyst selected from the group consisting of carbides, nitrides, oxycarbides, oxynitrides, and oxycarbonitrides. The transition metal is selected from the group consisting of metals from Group IVA, VA, VIA of the Periodic Table of the Elements. U.S. Pat. No. 6,235,962 B1 discloses a catalyst for ring opening which comprises a carrier consisting of alumina, a metal modifier selected from the group consisting of scandium, yttrium and lanthanum, and at least one catalytically active metal selected from the group consisting of platinum, palladium, rhodium, rhenium, iridium, ruthenium, and cobalt. U.S. Pat. No. 5,382,730 discloses a process for ring opening and isomerization of hydrocarbons where the catalyst comprises an aluminosilicate zeolite such as Zeolite Y or Zeolite Beta and a hydrogenation component. U.S. Pat. No. 5,345,026 discloses a process for conversion of cyclic hydrocarbons to non-cyclic paraffin hydrocarbons where the catalyst comprises a hydrogenation-dehydrogenation component and an acidic solid component comprising a group IVB metal oxide modified with an oxyanion of a group VIB metal. U.S. Pat. No. 3,617,511 discloses a catalyst for conversion of cyclic hydrocarbons to paraffins where the catalyst comprises rhodium or ruthenium on a halogen promoted refractory oxide. U.S. Pat. No. 6,241,876 discloses a ring opening catalyst which comprises a large pore crystalline molecular sieve component with a faujasite structure and an alpha acidity of less than one and a Group III noble metal. US 2002/43481 A1 discloses a catalyst for naphthalene ring opening which comprises at least one Group VIII metal selected from iridium, platinum, rhodium and ruthenium on a refractory inorganic oxide substrate containing at least one of an alkali metal and alkaline earth metal. US 2002/40175 A1 discloses a naphthene ring opening catalyst comprising a Group VIII metal selected from iridium, platinum, palladium, rhodium, ruthenium and combinations thereof. With the metal being supported on the substrate TO comprising at least one of a Group IB, IIB, and IVA metal. Finally, U.S. Pat. No. 4,859,312 discloses a process for cracking heavy oils using a catalyst comprising a SAPO molecular sieve and a platinum or palladium component.

Applicants have developed an improved catalyst which takes cyclic paraffins such as methylcyclohexane and converts them to normal paraffins of substantially the same carbon number. The catalyst comprises a Group VIII metal such as platinum or palladium, a molecular sieve and a refractory inorganic oxide component. The molecular sieve is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof.

SUMMARY OF THE INVENTION

As stated, this invention relates to a process and catalyst for ring opening, i.e. cleaving naphthenic rings. Accordingly, one embodiment of the invention is a process for producing acyclic paraffins from cyclic paraffins comprising contacting a feed stream comprising cyclic paraffins with a catalyst comprising a catalytic metal component, a refractory inorganic oxide component and a molecular sieve characterized in that it has an OH peak shift in its COFTIR spectrum of less than 310 cm⁻¹ and is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof at ring opening conditions to convert at least a portion of the cyclic paraffins to acyclic paraffins.

Another embodiment of the invention is a catalyst for opening cyclic paraffins comprising a catalytic metal component, a molecular sieve characterized in that it has an OH shift in its COFTIR spectrum of less than 310 cm⁻¹ and a refractory inorganic oxide component, the molecular sieve selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof.

These and other objects and embodiments will become clearer after a detailed description of the invention.

DETAILED DESCRIPTION OF THE INVENTION

One aspect of the present invention is a catalyst which is useful for opening or cleaving naphthenic rings. Ring opening as used herein refers to the breaking of one C—C bond in the ring without any further C—C bond breaks. The further breaking of C—C bonds is commonly referred to as cracking and is specifically excluded from the definition of ring opening. Accordingly, the major product of a ring opening reaction is an acyclic, e.g. normal or branched, paraffin having substantially the same molecular weight or the same number of carbon atoms as the starting cyclic paraffin or naphthene.

In order to carry out such a reaction, the catalyst of the present invention comprises a catalytic Group VIII metal component, a molecular sieve and a refractory inorganic oxide component. The function of the Group VIII metal component is to catalyze the C—C bond break, while the molecular sieve's function is to isomerize cyclohexane rings, both substituted and unsubstituted to cyclopentane rings. The refractory inorganic oxide can act as a support for the catalytic metal component and act as a binder when forming the catalyst into a shaped article. The molecular sieve is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof. The common characteristic of these molecular sieves is that they have sufficient acidity, i.e. acid site strength, to isomerize cyclohexanes to cyclopentanes but not so much acidity that they promote cracking of the acyclic paraffins to lower molecular weight products, i.e. lower carbon number.

One way to determine the acidity of a molecular sieve is to use Fourier Transform Infra Red (FTIR) Spectroscopy, specifically carbon monoxide (CO-FTIR) spectroscopy. Carbon monoxide, when adsorbed at liquid nitrogen temperatures, has been shown to be a suitable probe for measuring relative strengths of Brönsted acid sites in molecular sieve samples. CO forms H-bonded complexes with hydroxyl groups that are easily detected by infrared spectroscopy in both the O—H and C—O stretching regions. When CO adsorbs on a hydroxyl group at liquid nitrogen temperatures, the O—H bond is strongly perturbed and the stretching band is broadened and shifted to lower frequency. The magnitude of this shift is proportional to the strength of the acidic proton. It has been found that molecular sieves with an OH peak shift with CO addition of less than 310 cm⁻¹ and preferably less than 270 cm⁻¹ produce the greatest amount of paraffins with carbon chain lengths equivalent to the original ring-opened naphthenes, i.e. minimal or no cracking. Of course it is understood that only those MAPSOs and SAPOs included within the scope of the invention are those that meet the above acidity criteria. Specific SAPOs included in the scope of the invention are SAPO-11, SM-3 and SAPO-34.

MAPSOs molecular sieves are disclosed in U.S. Pat. No. 4,758,419 which is incorporated by reference in its entirety. A preferred MAPSO is MAPSO-31. SAPO molecular sieves are disclosed in U.S. Pat. No. 4,440,871 which is incorporated by reference in its entirety and SM-3 is described in U.S. Pat. No. 4,943,424 which is incorporated by reference in its entirety. UZM-8 is described in application Ser. No. 10/395,466 while UZM-8HS is described in application Ser. No. 10/395,624; UZM-15 and UZM-15HS are described in application Ser. No. 10/395,399; UZM-16 and UZM-16HS are described in application Ser. No. 10/395,639, all of which are incorporated by reference in their entirety. These compositions will be collectively referred to as UZM zeolites. All of the UZM zeolites have a microporous crystalline structure of at least AlO₂ and SiO₂ tetrahedral units. UZM-8, UZM-15 and UZM-16 have a composition on an as-synthesized and anhydrous basis expressed by an empirical formula of:

M_(m) ^(n+)R_(r) ^(p+)Al_(1-x)E_(x)Si_(y)O_(z)  (1).

M is at least one exchangeable cation selected from the group consisting of alkali and alkaline earth metals, “m” is the mole ratio of M to (Al+E) and, “n” is the weighted average valence of M. R is defined as follows:

-   -   1) UZM-8: R is at least one organoammonium cation selected from         the group consisting of quaternary ammonium cations,         diquaternary ammonium cations, protonated amines, protonated         diamines, protonated alkanolamines and quaternized         alkanolammonium cations, “r” is the mole ratio of R to (Al+E).     -   2) UZM-15: R is at least one first quaternary organoammonium         cation comprising at least one organic group having at least two         carbon atoms, and optionally a second organoammonium cation         selected from the group consisting of quaternary ammonium         cations, protonated amines, protonated diamines, protonated         alkanolamines, diquaternaryammonium cations, quaternized         alkanolamines and mixtures thereof, “r” is the mole ratio of R         to (Al+E); and     -   3) UZM-16: R is benzyltrimethylammonium (BzTMA) cation or a         combination of BzTMA and at least one organoammonium cation         selected from the group consisting of quaternary ammonium         cations, protonated amines, protonated diamines, protonated         alkanolamines, diquaternaryammonium cations, quaternized         alkanolamines and mixtures thereof, “r” is the mole ratio of R         to (Al+E).

E is an element selected from the group consisting of Ga, Fe, In, Cr, B, and mixtures thereof. The other variables are defined as “p” is the weighted average valence of R; “x” is the mole fraction of E, “y’ is the mole ratio of Si to (Al+E) and “z” is the mole ratio of O to (Al+E). The values of “m”, “n”, “r”, “p”, “x”, “y” and “z” are presented in Table A.

TABLE A Variable UZM-8 UZM-15 UZM-16 m 0 to about 2.0 0 to about 2.0 0 to about 0.75 n about 1 to about 2 about 1 to about 2 about 1 to about 2 r about 0.05 to about 0.25 to about about 0.25 to about 5.0 5.0 about 5.0 p about 1 to about 2 about 1 to about 2 about 1 to about 2 x 0 to about1.0 0 to about 1.0 0 to about 1.0 y about 6.5 to about about 7 to about 50 about 3 to about 35 2.5 z (m · n + r · p + (m · n + r · p + 3 + (m · n + r · p + 3 + 3 + 4 · y)/2 4 · y)/2 4 · y)/2

These zeolites are also characterized by x-ray diffraction patterns having at least the d-spacings and relative intensities set forth in Table B (UZM-8), Table C (UZM-15) and Table D (UZM-16).

TABLE B (UZM-8) 2-θ d(Å) I/I₀ % 6.40-6.90 13.80-12.80 w-s 6.95-7.42 12.70-11.90 m-s 8.33-9.11 10.60-9.70  w-vs 19.62-20.49 4.52-4.33 m-vs 21.93-22.84 4.05-3.89 m-vs 24.71-25.35 3.60-3.51 w-m 25.73-26.35 3.46-3.38 m-vs

TABLE C (UZM-15) 2-θ d(Å) I/Io % 8.35-9.30 10.58-9.50  w-m 12.30-13.30 7.19-6.65 w-m 16.60-17.20 5.34-5.15 w-m 19.00-19.80 4.67-4.48 w-m 20.80-22.30 4.27-3.98 w 23.55-23.95 3.77-3.71 w-m 24.03-24.47 3.70-3.63 w-m 25.50-26.25 3.49-3.39 vs 48.30-49.10 1.88-1.85 w

TABLE D (UZM-16) 2-θ d(Å) I/I₀ % 3.86-4.22 22.87-20.92 w-m 7.60-7.84 11.62-11.27 s-vs 11.58-11.86 7.64-7.46 w-m 13.29-13.54 6.65-6.53 m 13.90-14.20 6.36-6.23 w 15.34-15.68 5.77-5.65 m 19.30-19.65 4.60-4.51 m 20.37-20.73 4.35-4.28 m-s 23.18-23.54 3.83-3.78 m-s 23.57-23.89 3.77-3.72 s-vs 24.68-25.03 3.60-3.55 m-s 26.84-27.23 3.32-3.27 m 28.15-28.58 3.17-3.12 m 31.25-31.71 2.86-2.82 vs 33.37-33.76 2.68-2.65 w 35.89-36.36 2.50-2.47 m 48.05-48.52 1.89-1.87 w-m 51.38-51.90 1.78-1.76 w-m 55.35-56.04 1.66-1.64 w-m 58.08-58.64 1.59-1.57 w

The UZM-8, UZM-15 and UZM-16 zeolites are prepared by a hydrothermal crystallization of a reaction mixture prepared by combining reactive sources of R, aluminum, silicon and optionally M and E. The sources of aluminum include but are not limited to aluminum alkoxides, precipitated aluminas, aluminum metal, sodium aluminate, organoammonium aluminates, aluminum salts and alumina sols. Specific examples of aluminum alkoxides include, but are not limited to aluminum ortho sec-butoxide and aluminum ortho isopropoxide. Sources of silica include but are not limited to tetraethylorthosilicate, colloidal silica, precipitated silica, alkali silicates and organoammonium silicates. A special reagent consisting of an organoammonium aluminosilicate solution can also serve as the simultaneous source of Al, Si, and R. Sources of the E elements include but are not limited to alkali borates, boric acid, precipitated gallium oxyhydroxide, gallium sulfate, ferric sulfate, ferric chloride, chromium nitrate and indium chloride. Sources of the M metals include the halide salts, nitrate salts, acetate salts, and hydroxides of the respective alkali or alkaline earth metals. R can be introduced as an organoammonium cation or an amine. When R is a quaternary ammonium cation or a quaternized alkanolammonium cation, the sources include but are not limited to the hydroxide, chloride, bromide, iodide and fluoride compounds. Specific examples include without limitation DEDMA hydroxide, ETMA hydroxide, tetramnethylammonium hydroxide, tetraethylammonium hydroxide, hexamethonium bromide, tetrapropylammonium hydroxide, methyltriethylammonium hydroxide, tetramethylammonium chloride, propylethyldimethylammonium hydroxide (PEDMAOH), trimethylpropylammonium hydroxide, trimethylbutylammonium hydroxide (TMBAOH), N,N,N,N′,N′,N′-hexamethyl 1,4 butanediammonium hydroxide (DQ4), and choline chloride. The source of R may also be neutral amines, diamines, and alkanolamines that subsequently hydrolyzes to form an organoammonium cation. Specific examples are triethanolamine, triethylamine, and N,N,N′,N′ tetramethyl-1,6-hexanediamine. Preferred sources of R without limitation are ETMAOH, DEDMAOH, and HM(OH)₂,

In a special case, a reagent in the form of an aluminosilicate stock solution may be used. These solutions consist of one or more organoammonium hydroxides and sources of silicon and aluminum that are processed to form a clear homogenous solution that is generally stored and used as a reagent. The reagent contains aluminosilicate species that typically don't show up in zeolite reaction mixtures derived directly from separate sources of silicon and aluminum. The reagent is generally alkali-free or contains alkali at impurity levels from the silicon, aluminum, and organoammonium hydroxide sources. One or more of these solutions may be used in a zeolite synthesis. In the case of substitution of Al by E, the corresponding metallosilicate solution may also be employed in a synthesis.

As shown above, not all the R cations can produce all of the three UZM structures. Thus the preparation of UZM-15 requires at least one first organoammonium cation having at least one organic group with at least two carbon atoms, e.g. DEDMA, ETMA, TMBA, DQ4 and PEDMA and optionally (in addition to the first organoammonium cation) a second organoammonium compound. The preparation of UZM-16 requires benzyltrimethylammonium (BzTMA) or a combination of BzTMA and at least one organoammonium cation as described above.

The reaction mixture containing reactive sources of the desired components can be described in terms of molar ratios of the oxides by the formula:

aM_(2/n)O:bR_(2/p)O:(l-c)Al₂O₃ :cE₂O₃ :dSiO₂ :eH₂O.

The values of the variables for the UZM-8, 15 and 16 are presented in Table E along with general and preferred reaction conditions. The reaction mixtures are reacted at the stated conditions in a sealed reaction vessel under autogenous pressure.

TABLE E Reaction Mixture Compositions and Reaction Conditions for UZM Zeolites Variable UZM-8 UZM-15 UZM-16 a 0 to about 25 0 to about 5 0 to about 5 b about 1 to about 80 about 1.5 to about 80 about 1 to about 120 c 0 to about 1.0 0 to about 1.0 0 to about 1.0 d about 10 to about 100 about 10 to about about 5 to about 100 100 e about 100 to about about 100 to about about 50 to about 1500 1500 1500 Temp (° C.) - broad about 85° C. to about about 85° C. to about about 80° C. to about range 225° C. 225° C. 160° C. Temp (° C.) - about 125° C. to about about 140° C. to about 95° C. to about preferred range 150° C. about 175° C. 125° C. Time - broad range about 1 day to about about 12 hrs. to about 2 days. to 28 days about 20 days about 30 days Time - preferred about 5 days to about about 2 days to about 5 days to range 14 days about 10 days about 15 days

After crystallization is complete, the solid product is isolated from the heterogeneous mixture by means such as filtration or centrifugation, and then washed with de-ionized water and dried in air at ambient temperature up to about 100° C.

As-synthesized, the zeolites will contain some of the exchangeable or charge balancing cations in its pores. These exchangeable cations can be exchanged for other cations, or in the case of organic cations, they can be removed by heating under controlled conditions. Ion exchange involves contacting the zeolites with a solution containing the desired cation (at molar excess) at exchange conditions. Exchange conditions include a temperature of about 15° C. to about 100° C. and a time of about 20 minutes to about 50 hours. Calcination conditions include a temperature of about 300° C. to about 600° C. for a time of about 2 to about 24 hours.

A special treatment for removing organic cations which provides the ammonium form of the zeolite is ammonia calcination. Calcination in an ammonia atmosphere can decompose organic cations, presumably to a proton form that can be neutralized by ammonia to form the ammonium cation. The resulting ammonium form of the zeolite can be further ion-exchanged to any other desired form. Ammonia calcination conditions include treatment in the ammonia atmosphere at temperatures between about 250° C. and about 600° C. and more preferably between about 250° C. and about 450° C. for times of 10 minutes to 5 hours. Optionally, the treatments can be carried out in multiple steps within this temperature range such that the total time in the ammonia atmosphere does not exceed 5 hours. Above 500° C., the treatments should be brief, less than a half hour and more preferably on the order of 5-10 minutes. Extended calcination times above 500° C. can lead to unintended dealumination along with the desired ammonium ion-exchange and are unnecessarily harsh as most organoammonium templates easily decompose at lower temperatures.

The UZM-8HS, UZM-15HS and UZM-16HS zeolites are prepared from their respective parent zeolite by a number of various techniques and are represented by the empirical formula:

Ml_(a) ^(n+)Al_((1-x))E_(x)Si_(y′)O_(z″)  (2).

In formula (2), E and “x” are as defined above. Ml is at least one exchangeable cation selected from the group consisting of alkali metals, alkaline earth metals, rare earth metals, ammonium ion, hydrogen ion and mixtures thereof, a is the mole ratio of Ml to (Al+E), n is the weighted average valence of Ml, y′ is the mole ratio of Si to (Al+E) and z″ is the mole ratio of O to (Al+E). The values of the variables for the three zeolites are presented below in Table F.

TABLE F Variable UZM-8HS UZM-15HS UZM-16HS a about 0.05 to about 0.01 to about 0.01 to about 50 about 50 about 50 n about 1 to about 3 about 1 to about 3 about 1 to about 3 y′ greater than greater than about 7 greater than about 3 about 6.5 z″ (a · n + 3 + (a · n + 3 + 4 · y′)/2 (a · n + 3 + 4 · y′)/2 4 · y′)/2

The value of y′ is greater than the specific value set forth in Table F to virtually pure silica. By virtually pure silica is meant that virtually all the aluminum and/or the E metals have been removed from the framework. It is well know that it is virtually impossible to remove all the aluminum and/or E metal. Numerically, a zeolite is virtually pure silica when y′ has a value of at least 3,000, preferably 10,000 and most preferably 20,000. Thus, ranges for y′ are from 3 or 6.5 or 7 to 3,000 preferably greater than 10 to about 3,000; 3 or 6.5 or 7 to 10,000 preferably greater than 10 to about 10,000 and 3 or 6.5 or 7 to 20,000 preferably greater than 10 to about 20,000.

The zeolites UZM-8HS, UZM-15HS and UZM-16HS are further characterized by an x-ray diffraction pattern having at least the d-spacings and relative intensities set forth in Tables G, H and I respectively.

TABLE G UZM-8HS 2-θ d(Å) I/I_(o) % 6.90-7.40  12.8-11.94 w-vs 8.15-8.85 10.84-9.98  m-vs 14.10-14.70 6.28-6.02 w-vs 19.40-20.10 4.57-4.41 w-s 22.00-22.85 4.04-3.89 m-vs 24.65-25.40 3.61-3.50 w-m 25.70-26.50 3.46-3.36 w-vs

TABLE H UZM-15HS 2-θ d(Å) I/I_(o) %  8.75-10.30 10.12-8.60  w-vs 12.70-13.40 6.98-6.62 m-s 19.00-20.30 4.68-4.38 w 25.50-26.50 3.50-3.37 m-vs

TABLE I UZM-16HS 2-θ d(Å) I/I₀ % 7.70-8.40 11.47-10.52 m-vs 11.70-12.10 7.56-7.31 w 13.35-14.56 6.63-6.08 s-vs 20.60-21.70 4.31-4.09 w 24.60-25.65 3.62-3.47 m-s

The UZM-8HS, 15HS and 16HS are prepared by removing aluminum and optionally inserting silicon into the structure thereby increasing the Si/Al ratio and thus modifying the acidity and ion exchange properties of the zeolites. These treatments include: a) contacting with a fluorosilicate solution or slurry; b) calcining or steaming followed by acid extraction or ion-exchange; c) acid extraction or d) any combination of these treatments in any order.

Fluorosilicate treatment is known in the art and is described in U.S. Pat. No. 6,200,463 B1, which cites U.S. Pat. No. 4,711,770 as describing a process for treating a zeolite with a fluorosilicate salt. Both patents are incorporated by reference in their entirety. General conditions for this treatment are contacting the zeolite with a solution containing a fluorosilicate salt such as ammonium fluorosilicate (AFS) at a temperature of about 20° C. to about 90° C.

The acids which can be used in carrying out acid extraction include without limitation mineral acids, carboxylic acids and mixtures thereof. Examples of these include sulfuric acid, nitric acid, ethylenediaminetetraacetic acid (EDTA), citric acid, oxalic acid, etc. The concentration of acid which can be used is not critical but is conveniently between about 1 wt. % to about 80 wt. % acid and preferably between 5 wt. % and 40 wt. % acid. Acid extraction conditions include a temperature of about 10° C. to about 100° C. for a time of about 10 minutes to about 24 hours. Once treated with the acid, the treated UZM zeolite is isolated by means such as filtration, washed with deionized water and dried at ambient temperature up to about 100° C.

The extent of dealumination obtained from acid extraction depends on the cation form of the starting UZM as well as the acid concentration and the time and temperature over which the extraction is conducted. For example, if organic cations are present in the starting UZM zeolite, the extent of dealumination will be slight compared to a UZM zeolite in which the organic cations have been removed. This may be preferred if it is desired to have dealumination just at the surface of the UZM zeolite. As stated above, convenient ways of removing the organic cations include calcination, ammonia calcination, steaming and ion exchange. Calcination, ammonia calcination and ion exchange conditions are as set forth above. Steaming conditions include a temperature of about 400° C. to about 850° C. with from about 1% to about 100% steam for a time of about 10 minutes to about 48 hours and preferably a temperature of about 500° C. to about 600° C., steam concentration of about 5 to about 50% and a time of about 1 to about 2 hours.

It should be pointed out that both calcination and steaming treatments not only remove organic cations, but can also dealuminate the zeolite. Thus, alternate embodiments for dealumination include: a calcination treatment followed by acid extraction and steaming followed by acid extraction. A further embodiment for dealumination comprises calcining or steaming the starting UZM-16 zeolite followed by an ion-exchange treatment. Of course an acid extraction can be carried out concurrently with, before or after the ion exchange.

The ion exchange conditions are the same as set forth above, namely a temperature of about 15° C. to about 100° C. and a time of about 20 minutes to about 50 hours. Ion exchange can be carried out with a solution comprising a cation (Ml′) selected from the group consisting of alkali metals, alkaline earth metals, rare earth metals, hydrogen ion, ammonium ion, and mixtures thereof. By carrying out this ion exchange, the Ml cation is exchanged for a secondary or different Ml′ cation. In a preferred embodiment, the UZM-16HS composition after the steaming or calcining steps is contacted with an ion exchange solution comprising an ammonium salt. Examples of ammonium salts include but are not limited to ammonium nitrate, ammonium chloride, ammonium bromide, and ammonium acetate. The ammonium ion containing solution can optionally contain a mineral acid such as but not limited to nitric, hydrochloric, sulfuric and mixtures thereof. The concentration of the mineral acid is that amount necessary to give a ratio of H⁺ to NH₄ ⁺ of 0 to 1. This ammonium ion exchange aids in removing any debris present in the pores after the steaming and/or calcination treatments.

It is apparent from the foregoing that, with respect to effective process conditions, it is desirable that the integrity of the zeolite crystal structure be substantially maintained throughout the dealumination process, and that the zeolite retains at least 50%, preferably at least 70% and more preferably at least 90% of its original crystallinity. A convenient technique for assessing the crystallinity of the products relative to the crystallinity of the starting material is the comparison of the relative intensities of the d-spacing of their respective X-ray powder diffraction patterns. The sum of the peak intensities, in arbitrary units above the background, of the starting material is used as the standard and is compared with the corresponding peak intensities of the products. When, for example, the numerical sum of the peak heights of the molecular sieve product is 85 percent of the value of the sum of the peak intensities of the starting zeolite, then 85 percent of the crystallinity has been retained. In practice it is common to utilize only a portion of the peaks for this purpose, as for example, five or six of the strongest peaks. Other indications of the retention of crystallinity are surface area and adsorption capacity. These tests may be preferred when the substituted metal significantly changes, e.g., increases, the absorption of x-rays by the sample or when peaks experience substantial shifts such as in the dealumination process.

After having undergone any of the dealumination treatments as described above, the UZM zeolite is usually dried and can be used as discussed below. The properties of the modified UZM zeolite can be further modified by one or more additional treatment. These treatments include steaming, calcining or ion exchanging and can be carried out individually or in any combination. Some of these combinations include but are not limited to:

The dealumination treatment described above can be combined in any order to provide zeolites useful in the invention although not necessarily with equivalent result. It should be pointed out that the particular sequence of treatments, e.g., AFS, acid extraction, steaming, calcining, etc can be repeated as many times as necessary to obtain the desired properties. Of course one treatment can be repeated while not repeating other treatments, e.g., repeating the AFS two or more times before carrying out steaming or calcining; etc. Finally, the sequence and/or repetition of treatments will determine the properties of the final UZM-8HS, 15HS or 16HS composition.

In specifying the proportions of the molecular sieve starting material or adsorption properties of the molecular sieve product and the like herein, the “anhydrous state” of the molecular sieve will be intended unless otherwise stated. The term “anhydrous state” is employed herein to refer to a molecular sieve substantially devoid of both physically adsorbed and chemically adsorbed water.

A second component of the catalyst of the invention is a catalytic metal component. The catalytic metal component is selected from the metals of Group VIII (Groups 8, 9 and 10 of the IUPAC designation) of the Periodic Table of the Elements and preferably from the noble metals. The group of noble metals are ruthenium, rhodium, palladium, platinum, iridium and osmium. Preferred catalytic metals are platinum, palladium, rhodium ruthenium, iridium and mixtures thereof.

The catalytic metal component can be deposited either on the molecular sieve or on a refractory inorganic oxide component. Inorganic oxides which can be used are any of those well known in the art and include but are not limited to aluminas, silica/alumina, silica, titania, calcium oxide and magnesium oxide, clays and zirconia. In order to avoid confusion it is pointed out that the term silica/alumina does not mean a physical mixture of silica and alumina but means an acidic and amorphous material that has bee cogelled or coprecipitated. The term is well known in the art, see e.g. U.S. Pat. No. 3,909,450; U.S. Pat. No. 3,274,124 and U.S. Pat. No. 4,988,659. The aluminas which can be used include gamma alumina, theta alumina, delta and alpha alumina.

The catalytic metal component is deposited onto either the molecular sieve or inorganic oxide by means well known in the art such as spray impregnation or evaporative impregnation. Both spray or evaporative impregnation use a solution containing a decomposable compound of the desired metal. By decomposable is meant that upon heating the compound decomposes to provide the catalytic metal or catalytic metal oxide. Non-limiting examples of decomposable compounds which can be used include chloroplatinic acid, palladic acid, chloroiridic acid, rhodium trichloride, ruthenium tetrachloride, osmium trichloride, iron chloride, cobalt chloride, nickel chloride, iron nitrate, cobalt nitrate, nickel nitrate, rhodium nitrate, ammonium chloroplatinate, platinum tetrachloride hydrate, palladium chloride, palladium nitrate, tetraamine platinum chloride and tetraamminepalladium (II) chloride. The solvent which is used to prepare the solution is usually water although organic solvents such as alcohols, dimethyl formamide (DMF), dimethylsulfoxide (DMSO), tetrahydrofuran (THF) and amines, e.g., pyridine can be used.

Spray impregnation involves taking a small volume of the solution and spraying it over the support (molecular sieve or oxide) while the support is moving. When the spraying is over, the wetted support can be transferred to other apparatus for drying or finishing steps.

One particular method of evaporative impregnation involves the use of a steam-jacketed rotary dryer. In this method the support is immersed in the impregnating solution which has been placed in the dryer and the support is tumbled by the rotating motion of the dryer. Evaporation of the solution in contact with the tumbling support is expedited by applying steam to the dryer jacket. The impregnated support is then dried at a temperature of about 60° C. to about 300° C. and then calcined at a temperature of about 300° C. to about 850° C. for a time of about 30 minutes to about 8 hours to give the calcined catalyst.

When the molecular sieve is the support, the catalytic metal component can also be deposited thereon by ion-exchange. Ion-exchange is carried out by contacting the molecular sieve with a solution containing a compound of the desired metal at ion-exchange conditions which include a temperature of about 20° C. to about 100° C. for a time from about 5 minutes to about 6 hours.

When the catalytic metal component is deposited on the refractory inorganic oxide component, the catalyst comprises separate particles. One configuration is a loose mixture of the two particles (refractory oxide and molecular sieve particles) or the particles are mixed and then formed into shaped articles such as cylinders, pellets, pills, spheres, irregularly shaped particles, etc. Methods of preparing such shaped articles are well known in the art. In the case where the catalytic metal is deposited on the molecular sieve, then the inorganic oxide acts as a binder so that the resultant mixture can be formed into any of the shapes described above.

In another embodiment, the molecular sieve and inorganic oxide are first mixed and formed into a shaped article and then the catalytic metal is deposited onto the composite article by any of the means described above. In this case, the catalytic metal is believed to be deposited on both the inorganic oxide and molecular sieve supports. Regardless of how and where the catalytic metal is deposited, it is present in the final catalyst in an amount from about 0.01 to about 10 weight percent of the catalyst expressed as the metal. It should also be pointed out that the metal component can be present on the catalyst in its elemental (zero valent) state or as the oxide.

The catalyst may optionally contain a modifier which modifies the activity of the catalytic metal. The modifier is selected from the group consisting of titanium, niobium, rare earth elements, tin, rhenium, zinc, germanium and mixtures thereof. Preferred rare earth elements are cerium, ytterbium, lanthanum, dysprosium and mixtures thereof. The modifier component is deposited by the same techniques as described above for the catalytic metals. Further, the modifier can be deposited on the support before, after or simultaneously with the catalytic metal, although not necessarily with equivalent results. It is preferred to deposit the modifier with the catalytic metal. The amount of modifier can vary substantially but is usually in the range of about 0.1 to about 50 wt. %, preferably about 1 to about 10 wt. % of the catalyst as the element.

The catalyst described above is used in a process where cyclic paraffins are opened or cleaved to acyclic paraffins. The feeds which can be used in the ring opening process are any of those which comprise C₅-C₆ aliphatic rings, i.e. naphthenic rings. Depending on the source feeds can contain from about 15% to about 55% naphthenes.

The feedstream is contacted with the catalyst at ring opening conditions which include a temperature of about 200° C. to about 600° C. with a range of about 375° C. to about 415° C. being preferred, a pressure of about atmospheric to about 20,684 kPag (3000 psig) preferably from about 3447 kPa (500 psig) to about 13790 kPa (2000 psig) and most preferably from about 4826 kPa (700 psig) and about 6205 (900 psig), a liquid hourly space velocity of about 0.1 to about 30 hr⁻¹, preferably about 2 to about 10 hr⁻¹ and most preferably from about 4 to about 6 hr⁻¹ and H₂/HC (hydrocarbon) molar ratio from about 0.1 to about 30, preferably from about 1 to about 10 and most preferably from about 5 to about 7.

The following examples are presented in illustration of this invention and are not intended as undue limitations on the generally broad scope of the invention as set out in the appended claims.

EXAMPLE 1

Aluminum tri-sec-butoxide (95%), 46.32 g, was added to 626.31 g diethyldimethylammonium hydroxide (20%) and dissolved with vigorous stirring. To this mixture, 142.5 g precipitated silica, Ultrasil™ VNSP3 (85% SiO₂), was added with continuous stirring. In a separate beaker, 21.47 g TMACl (97%) and 5.22g NaCl were dissolved in 58.18 g de-ionized H₂O. This solution was then added to the previous reaction mixture. The resulting mixture was homogenized for 20 min and the final reaction mixture was then distributed among several autoclaves including one 0.6L stainless steel stirred autoclave. The 0.6L autoclave was heated to and held at 150° C. for 120 hr. after which the solids were collected by centrifugation, washed with de-ionized water and dried at 95° C.

The products isolated from the 0.6L reaction exhibited an x-ray diffraction pattern consistent with the characteristic lines for the zeolite designated UZM-15. A sample of the UZM-15 (60 g) was then mixed with 120 ml of 1.57 M HCl solution and heated to 95° C. for 1 hour to remove a good portion of organic templates. The slurry was then filtered while still hot and washed with 500 ml of de-ionized H₂O. The filter cake was air dried overnight, treated with HCl as described above, washed using two 500 ml portions of de-ionized H₂O and dried at 95° C.

Extrudates of 70 wt. % zeolite (UZM-15) and 30% alumina were prepared by first mulling 19.1 grams of Condea SB™ alumina with 29.0 grams of 20% HNO₃. The HCl extracted UZM-15 (37.0 grams), Solka Floc (1.5 grams) extrusion aid and additional de-ionized H₂O were then added to the peptized alumina and mulled for additional time until a consistent dough texture was obtained. The dough was then pushed through a die plate with 1/16 inch diameter holes to form green extrudate, which was then activated first in N₂ and then air at 500° C. for 2 hours. This catalyst was identified as sample A.

EXAMPLE 2

An aluminosilicate reaction mixture was prepared by adding 35.2 grams of Al (Osec-Bu)₃ (95+%) to 927.5 grams BzTMAOH (40%), and then stirring for 20 minutes, followed by the slow addition of 416.5 grams of colloidal silica (LUDOX™ AS40, 40% SiO₂). The resulting mixture was then reacted in an autoclave at 125° C. for 120 hours. The solid product was recovered and washed, and showed an x-ray pattern consistent with that of UZM-16. The powder was then calcined at 500° C. and then NH₄NO₃ exchanged, filtered, washed with de-ionized H₂O and dried at 90° C. The catalyst comprising 70 wt. % UZM-16 and 30 wt. % Al₂O₃ was prepared using a procedure similar to that described in Example 1. This catalyst was identified as sample B.

EXAMPLE 3

An aluminosilicate reaction mixture was prepared in the following manner. Al(Osec-Bu)₃ (97%), 804.4 g, was added to 7330 g of DEDMAOH, (20% aq) with vigorous stirring. To this mixture, 2530 g precipitated silica, (Ultrasil™ VN SP3, 89% SiO₂) was added with continuous mixing. A solution of 127 g NaOH in 3115 g deionized H₂O was prepared and added to the previous mixture and homogenized for 30 min. The resulting mixture was reacted in an autoclave at 150° C. for 185 hours. The solid product was collected by filtration, washed with de-ionized water, and dried at 95° C. The product was identified as UZM-8 by powder x-ray diffraction analysis. The zeolite was first NH₄NO₃ exchanged to remove sodium, then prepared into a catalyst of 70 wt. % UZM-8 and 30 wt. % Al₂O₃ using a procedure similar to that described in Example 1. This catalyst was identified as sample C.

EXAMPLE 4

An aluminosilicate reaction mixture was prepared in the following manner. Al(Osec-Bu)₃ (97%), 66.51 g, was added to 918.29 g of DEDMAOH, (20% aq) with vigorous stirring. To this mixture, 208.95 g precipitated silica, (Ultrasil™ VN SP3, 89% SiO₂) was added with continuous mixing. A solution of 37.2 g Na₂SO₄ in 169.05 g deionized H₂O was prepared and added to the previous mixture and homogenized for 10 min. A 1.7 g portion of UZM-8 seed was added to the mixture, followed by an additional 20 min of mixing. A 1077.3 g portion of this final reaction mixture was transferred to a 2-L Teflon-lined autoclave. The autoclave was placed in an oven set at 150° C. and the mixture was reacted quiescently for 10 days. The solid product was collected by filtration, washed with de-ionized water, and dried at 95° C. The product was identified as UZM-8 by powder x-ray diffraction analysis. The zeolite was first NH₄NO₃ exchanged to remove sodium, then prepared into a catalyst of 70 wt. % UZM-8 and 30 wt. % Al₂O₃ using a procedure similar to that described in Example 1. This catalyst was identified as sample D.

EXAMPLE 5

In a container 219.3 g of alumina were mixed with 12.9 g of HNO₃ (70%) and to this peptized mixture there were added 109.6 g of alumina, 84.3 g of SM-3 molecular sieve (prepared according to U.S. Pat. No. 4,943,424), 1.5 g of methacel A4M and 197.4 g water. The resulting dough was mixed for 35 minutes and then extruded through a 1/16 inch (0.16 cm) die. The extrudates were dried at 300° C. for 1 hour and then 550° C. for 2 hours in flowing air. This catalyst was identified as sample E.

EXAMPLE 6

A catalyst containing SAPO-11 and alumina was prepared per Example 5. The SAPO-11 was prepared according to U.S. Pat. No. 4,440,871. This catalyst was identified as sample F.

EXAMPLE 7

Platinum was dispersed on samples A to F by taking 8.35 g of each sample and contacting it with 15 ml of a solution containing 2.97 cc chloroplatinic acid (28.08 mg Pt/ml) and 0.569 ml HCl (37%) in a rotary evaporator. The solution was impregnated at 100° C. and the impregnated base was calcined at 525° C. in flowing air (3600 cc/min) and 45 cc/min HCl for 30 minutes. The calcined catalyst was reduced in flowing hydrogen 3000 cc/min H₂ at 500° C. for 1 hour. The amount of platinum on the finished catalyst was found to be about 1 wt. %. The catalysts were labeled catalysts A to F respectively.

EXAMPLE 8

Catalysts A to F were tested for methylcyclohexane ring opening activity and selectivity as follows. In on Incolloy™ tube reactor there were placed 3 g of 40-60 mesh crushed extrudates of each sample. The reactor was heated using an infrared furnace. Inert spacers were placed before the catalyst bed to minimize dead volume and pre-heat the feed. The feed consisted of methylcyclohexane (>98% purity) which was mixed with hydrogen carrier gas (>99% pure) in a heated mixing chamber and then flowed through the catalyst bed at a weight hourly space velocity of 5 hr⁻¹. Measurements were taken at various temperatures and a pressure of 5516 kPa (800 psi). The reactor effluent was analyzed by an on-line gas chromatograph and the results are presented in the Table below.

Catalysts A to F were also analyzed by CO-FTIR spectroscopy to determine their acid strength. The relative strengths of the Brönsted acid sites for this set of catalysts were measured using CO adsorption at low temperature (˜90K). The samples were pretreated to 550° C. in helium flow and then cooled to ˜90K and exposed to successive 0.5 cc doses of 0.1% CO in helium. The frequency shifts of the bridging hydroxyl groups after exposure to CO were determined by subtracting the FTIR spectrum recorded before CO exposure. The resulting difference spectra clearly show the resulting band shifts. The results of these measurements are also presented in the Table below.

Methylcyclohexane Activity for Several Catalysts C₇ C₇ C₇ OH band Temperature MCH Paraffin Paraffin Naphthene C₆-Yield Shift with Catalyst ID (° C.): Conversion Selectivity Yield Yield (no methane) CO (cm⁻¹) Catalyst A 384 88 46% 41.0 26.2 17.9 310 Catalyst B 412 89 46% 40.6 16.1 23.0 N/A Catalyst C 369 91 28% 25.5 29.9 15.4 320 Catalyst D 393 95  4% 4.3 10.7 77.7 322 Catalyst E 386 89 61% 54.3 13.9 18.7 263 Catalyst F 410 92 62% 56.7 6.6 23.4 264

An optimum ring-opening catalyst produces C7 paraffins at high MCH conversion. Therefore, good ring-opening catalysts are highly selective to C7 paraffins while minimizing loss of C7 products to lower molecular weight components through cracking. Catalysts E and F are the most selective to C7 paraffins at high MCH conversion while minimizing further cracking. This is possible because the acid strength of the molecular sieve component allows much ring isomerization but is weak enough to prevent further molecular weight reduction. This desirable acidity strength is characterized by the OH Band shift of <270 cm-1. Catalyst D also produces high conversion of MCH at temperatures similar to that used for Catalysts E and F but gives poor selectivity to the desired C7 paraffins. This catalyst has much stronger acidity as characterized by a shift in the OH Band of >310 cm-1 and this causes extensive cracking to C6-products. Therefore, the acid strength desired allows processing of MCH feed at temperatures high enough to produce C7 paraffins while minimizing cracking. 

1. A process for producing acyclic paraffins from cyclic paraffins comprising contacting a feed stream comprising cyclic paraffins with a catalyst comprising a catalytic metal component, a refractory inorganic oxide component and a molecular sieve characterized in that it has an OH peak shift in its CO FTIR spectrum of less than 310 cm⁻¹ and is selected from the group consisting of MAPSOs, SAPOs, UZM-8, UZM-8HS, UZM-15, UZM-15HS, UZM-16, UZM-16HS and mixtures thereof at ring opening conditions to convert at least a portion of the cyclic paraffins to acyclic paraffins.
 2. The process of claim 1 where the catalytic metal is selected from the group consisting of platinum, palladium, rhodium, ruthenium, iridium and mixtures thereof.
 3. The process of claim 1 where the catalyst is a physical mixture of molecular sieve particles and refractory inorganic oxide component particles.
 4. The process of claim 3 where the catalytic metal component is deposited on the molecular sieve.
 5. The process of claim 3 where the catalytic metal component is deposited on the oxide component which is selected from the group consisting of alumina, silica, silica/alumina, calcium oxide, magnesium oxide and mixtures thereof.
 6. The process of claim 1 where the catalyst is formed into a shaped article selected from the group consisting of pills, extrudates, spheres, irregularly shaped particles and tablets.
 7. The process of claim 1 where the catalytic metal component is present in an amount from about 0.01 to about 10 weight percent of the catalyst as the metal.
 8. The process of claim 1 where the catalyst further comprises a modifier component selected from the group consisting of titanium, niobium, rare earth elements, tin, rhenium, zinc, germanium and mixtures thereof.
 9. The process of claim 8 where the modifier component is present in an amount from about 0.1 to about 50 wt. % of the catalyst as the element.
 10. The process of claim 1 where the ring opening conditions include a temperature of about 200° C. to about 600° C. a pressure of about atmospheric to about 20,684 kPa and a liquid hourly space velocity of about 0.1 to about 30 hr⁻¹.
 11. The process of claim 8 where the rare earth element is selected from the group consisting of cerium, ytterbium, lanthanum, dysprosium and mixtures thereof. 